Disassembly and Assembly

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Place the transaxle clutch housing on a bench.
Remove the 2 vent bolts and the vent.

Fig 1: Locating Vent And Bolts
Courtesy of FORD MOTOR CO.
Using the special tools, remove the differential bearing cup.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 2: Locating Bearings And Cups Set
  Courtesy of FORD MOTOR CO.
Remove and discard the differential seal.
Using the special tools, remove the input shaft bearing cup.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 3: Using Special Tools To Remove Input Shaft Bearing Cup
  Courtesy of FORD MOTOR CO.
Using a screwdriver, remove and discard the input shaft oil seal.

Fig 4: Using Screwdriver To Remove Input Shaft Oil Seal
Courtesy of FORD MOTOR CO.
Remove the funnel and the output shaft bearing cup.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 5: Removing Funnel And Output Shaft Bearing Cup
  Courtesy of FORD MOTOR CO.
Remove the shift control selector plate bolts and the shift control selector plate.

Fig 6: Locating Shift Control Selector Plate And Bolts
Courtesy of FORD MOTOR CO.
Using a screwdriver, remove and discard the seal cap.
- An alternate method: make a small hole in the center of the cup and use a slide hammer and screw.
  
  Fig 7: Locating Hole
  Courtesy of FORD MOTOR CO.
Align the selector arm with the indentation in the case. Using a punch, remove the selector arm roll pin. Discard the roll pin.

Fig 8: Locating Selector Arm Roll Pin
Courtesy of FORD MOTOR CO.

NOTE: Slide the control arm rearward.

Fig 9: Removing Change Arm Roll Pin

Courtesy of FORD MOTOR CO.

Using a punch, remove the change arm roll pin. Discard the roll pin. Remove the control rod, the selector arm and the change arm.
Working on the transaxle case:
1. Remove the 2 shift lever bolts and separate the boot from the case.
2. Separate the shift arm and boot from the shift assembly.
  
  Fig 10: Identifying Shift Lever Bolts And Shift Arm
  Courtesy of FORD MOTOR CO.
Remove the control arm bolt. Pull the shift lever outward, then remove the washer, the spring, the control arm and the key.
- Inspect the all components for wear or damage. Install a new components as necessary.
  
  Fig 11: Locating Control Arm Bolt
  Courtesy of FORD MOTOR CO.
  
  Fig 12: Locating Washer, Spring, Control Arm And Key
  Courtesy of FORD MOTOR CO.
Remove the shift lever boot.

Fig 13: Locating Shift Lever Boot
Courtesy of FORD MOTOR CO.
Remove the input shaft bearing cup and shims.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set. Do not install one without the other.
Remove the output shaft bearing cup and shims.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set. Do not install one without the other.
Using the special tools, remove the differential bearing cup and shims.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 14: Using Special Tools To Remove Differential Bearing Cup And Shims
  Courtesy of FORD MOTOR CO.
Remove and discard the differential oil seal.

Fig 15: Locating Differential Oil Seal
Courtesy of FORD MOTOR CO.